Integrated air fiber hot-pressing shaping equipment and hot-pressing shaping method

Abstract

The invention belongs to the technical field of air fiber processing, and particularly relates to integrated air fiber hot-pressing shaping equipment and a hot-pressing shaping method. The hot-pressing shaping equipment structurally comprises a hot air unit, a mold pressing unit and a cutting unit, the hot air unit, the mold pressing unit and the cutting unit are connected through a conveying belt, and a cold air cooling device is arranged on the mold pressing unit. By means of the innovative process design, integrated operation of mold pressing shaping and cutting procedures is achieved, the production period is effectively shortened, and the production cost is reduced. Meanwhile, by means of the design of the replaceable mold, the production process is higher in flexibility, and the diversified requirements of the market for air fiber products of different shapes are met.

Description

Technical Field

[0001] This invention relates to the field of air fiber processing technology, specifically to an integrated air fiber hot pressing and shaping equipment and method, which aims to improve the production efficiency and product diversity of air fiber products. Background Technology

[0002] Current air fiber processing technology involves multiple complex and time-consuming steps from raw material pretreatment to final product output. This not only significantly reduces production efficiency but also extends product delivery cycles, making it difficult to meet market demands for rapid supply. Furthermore, existing technologies produce air fibers with relatively limited shapes, confined to a few common basic forms, which falls short in the face of increasingly diversified and personalized market demands. As the market rapidly changes, customer needs for air fibers are gradually shifting towards diversification and customization, but existing processes cannot keep pace with this trend. This often results in companies struggling to provide effective solutions to specific customer requirements, weakening their competitiveness in the market and limiting the industry's further development.

[0003] In summary, the traditional processing technology in the current air fiber processing industry has the following drawbacks: (1) The separation of hot pressing and cutting processes makes the production process lengthy; (2) Each process requires independent equipment and operating space, which not only results in a large equipment footprint, but also increases the number of product transfer links during the production process, consuming a lot of time and manpower, greatly reducing production efficiency and increasing production costs; (3) In addition, the molds used in the traditional process are mostly of fixed shape, making it difficult to quickly switch production modes when processing air fiber products of different shapes, and unable to respond to the market's demand for diversified products in a timely manner. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention aims to provide an integrated air fiber hot pressing and shaping equipment and method. Through innovative process design, it achieves integrated operation of molding and cutting processes, effectively shortening the production cycle and reducing production costs. Simultaneously, the interchangeable mold design provides greater flexibility to the production process, meeting the diverse market demands for air fiber products of different shapes.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] An integrated air fiber heat pressing and shaping device includes the following structure:

[0007] The unit comprises a hot air unit, a molding unit, and a cutting unit, which are connected by a conveyor belt. The molding unit is equipped with a cold air cooling device.

[0008] The specific structures are as follows:

[0009] Conveyor belt: Made of high-strength, high-temperature resistant and flexible rubber or special engineering plastics, with stepless speed adjustment to ensure that the core material is transported smoothly and at a uniform speed to each processing station.

[0010] Hot air unit: Hot air is generated via electric heating. To improve heat transfer efficiency, a circulating fan is installed within the hot air unit to create a continuous flow of hot air within the chamber, rapidly and evenly heating the core material. The overall protection system consists of over-temperature protection and an alarm device. When the actual temperature exceeds the control temperature, the hot air unit stops heating and issues an alarm, ensuring the integrity of the components and test pieces, as well as guaranteeing product quality and the stability of the production process.

[0011] Molding Unit: The main structure is made of high-strength alloy steel to ensure stability and safety under high pressure. Multiple molds can be installed for simultaneous production, improving efficiency. The mold mounting rack within the molding unit features a modular design for easy and quick replacement of molds of different shapes. The mold consists of upper and lower parts. The upper mold moves up and down via a pneumatic drive, and each mold can be controlled independently, saving energy to some extent. The pneumatic drive's pressure output accuracy reaches ±0.01 MPa, ensuring accurate pressurization to 0.15 MPa. The lower mold is fixed to the bottom of the molding unit, and its surface undergoes a special wear-resistant and corrosion-resistant treatment to extend its service life.

[0012] Cooling device: Composed of multiple high-performance air-cooled radiators and high-speed fans. The air-cooled radiators are made of aluminum alloy, which has excellent heat dissipation performance. This ensures that after molding, cool air can be quickly and evenly blown onto the core material, allowing it to cool and set in a short time.

[0013] Cutting Unit: Capable of mounting multiple cutting dies, equipped with high-precision linear guides and a pneumatic drive system to ensure smooth cutting and accurate positioning. The cutting dies are made of a special alloy material with high hardness and wear resistance, and can be replaced according to different cutting shapes and thickness requirements. The cutting dies are installed using a quick-positioning clamping device, enabling die replacement and adjustment to be completed within minutes.

[0014] An integrated air fiber hot pressing and setting method, utilizing the aforementioned integrated air fiber hot pressing and setting equipment for hot pressing and setting, includes the following process flow:

[0015] (1) The air fiber core material is laid flat on the conveyor belt. The operator clicks the start button and the conveyor belt starts running at the set speed.

[0016] (2) The conveyor belt smoothly transports the air fiber core material to the hot air unit. During this period, the heating element and the circulating fan of the hot air unit work together to fully wrap the core material with hot air and heat it to 80-120°C. The core material stays in the hot air unit for 30 seconds and gradually softens under the action of hot air, reaching a moldable state.

[0017] (3) The softened core material is then conveyed to the molding unit by the needle plate chain. The operator selects the corresponding mold according to the required product shape and installs it in the molding unit. When the core material reaches the molding position, the upper mold descends rapidly under the action of the pneumatic drive device and is pressurized to 0.1-0.3 MPa, with a holding time of 1-3 minutes. During the pressurization process, the upper and lower surfaces of the mold are in full contact with the core material, causing the core material to plastically deform and conform to the shape of the mold under pressure.

[0018] (4) After molding is completed, the cooling device is started. The high-speed fan blows the cold air through the air-cooled radiator to accelerate the cooling and then blows it evenly onto the core material in the mold. The cold air quickly cools the core material, and the upper mold rises rapidly under the action of the air pressure drive device to complete the shaping process.

[0019] (5) After cooling and shaping, the core material enters the cutting process. The operator installs the corresponding die according to the product shape, and the air pressure of the straight blade cutting unit drives the cutting blade to cut the core material according to the preset cutting path. During the cutting process, the linear guide rail ensures the straightness and accuracy of the blade movement, and guarantees the accuracy of the cutting dimensions.

[0020] (6) After cutting, the finished product is conveyed out by the conveyor belt. The operator performs quality inspection and packaging of the finished product, and the whole process is completed.

[0021] Beneficial effects

[0022] This invention discloses an integrated air fiber hot pressing and shaping equipment and method. Through innovative improvements, the equipment of this invention transforms traditional production methods into continuous and automated production. Compared to traditional processes, the equipment of this invention introduces an advanced automated control system, with each production stage closely integrated, eliminating the need for frequent manual intervention. This not only significantly reduces labor costs but also makes the production process more stable and efficient, greatly shortening production time and increasing output per unit time.

[0023] In terms of space utilization, the equipment described in this invention adopts an integrated design concept, consolidating multiple previously scattered production devices into an organic whole, reducing space waste between production devices and significantly reducing the floor space required. This design optimization makes it easier for enterprises to upgrade and renovate equipment within existing sites, reducing site costs and renovation difficulties for enterprises to expand production scale, saving enterprises a significant amount of resources and costs, and significantly enhancing the overall competitiveness of enterprises.

[0024] The integrated air fiber hot pressing and shaping equipment and method described in this invention have the following advantages compared with the prior art:

[0025] Improved production efficiency: By integrating molding and cutting processes on the same production line, the transfer time and waiting time between different processes are reduced, and production efficiency is increased by 30%-50% compared to traditional processes.

[0026] Cost reduction: The integrated equipment design reduces the number of devices and floor space required, while also reducing labor costs and energy consumption, resulting in a 20%-30% reduction in overall production costs.

[0027] Enhanced product diversity: The interchangeable mold design allows the production line to quickly switch or simultaneously produce air fiber products of different shapes, meeting the market demand for diversified products and improving the company's market competitiveness. Attached Figure Description

[0028] Figure 1 : A schematic diagram of the integrated air fiber hot pressing and shaping equipment described in this invention;

[0029] Figure 2 : A schematic diagram of the molding unit described in this invention;

[0030] Figure 3 : A schematic diagram of the cutting unit described in this invention;

[0031] Figure 4 : A schematic diagram of the zero-point positioning device of the present invention;

[0032] Figure 5 : A schematic diagram of the structure of the die-cutting mold described in this invention

[0033] Figure 6 : A schematic diagram of the structure of the mold described in this invention;

[0034] In the diagram, 1: Hot air unit; 2: Molding unit; 3: Cutting unit; 4: Conveyor belt; 5: Cold air cooling device; 6: Mold; 7: Cutting die; 8: Upper mold; 9: Lower mold; 10: Pneumatic drive system; 11: Zero point positioning device; 12: Precision pressure regulating valve; 13: Guide shaft; 14: Solenoid valve; 15: Positioning lasing plate; 16: Zero point positioning disc.

[0035] The mold 6 includes an upper mold 8 and a lower mold 9; the pneumatic drive system 10 includes a precision pressure regulating valve 12 to regulate pressure, a guide shaft 13 to specify the direction of mold movement, and a solenoid valve 14 to control the lifting and lowering of the cylinder; the zero-point positioning device 11 includes a positioning lasing 15 and a zero-point positioning disc 16. Detailed Implementation

[0036] The present invention will now be described in detail. Before proceeding with the description, it should be understood that the terminology used in this specification and the appended claims should not be construed as limited to its general or dictionary meaning, but rather should be interpreted according to the meaning and concept corresponding to the technical aspects of the invention, based on the principle that the inventors are allowed to appropriately define the terms for the best interpretation. Therefore, the description presented herein is merely a preferred example for illustrative purposes and is not intended to limit the scope of the invention. It should be understood that other equivalents or modifications can be obtained from it without departing from the spirit and scope of the invention.

[0037] The following embodiments are merely examples illustrating implementations of the present invention and do not constitute any limitation on the present invention. Those skilled in the art will understand that modifications made without departing from the spirit and concept of the present invention fall within the protection scope of the present invention. Unless otherwise specified, the reagents and instruments used in the following embodiments are commercially available products.

[0038] Example 1

[0039] An integrated air fiber heat pressing and shaping device, such as Figure 1 As shown, it includes the following structure: hot air unit 1, molding unit 2 and cutting unit 3. The hot air unit, molding unit and cutting unit are connected by a conveyor belt 4. The molding unit is equipped with a cold air cooling device 5.

[0040] The hot air unit generates hot air through electric heating. The hot air unit is also equipped with a circulating fan, which makes the hot air circulate in the hot air box, so as to heat the core material quickly and evenly.

[0041] The hot air unit is also equipped with a whole-machine protection system, which includes an over-temperature protection device and an alarm device. When the actual temperature exceeds the control temperature, the over-temperature protection device stops the hot air unit from heating, and the alarm device issues an alarm.

[0042] like Figure 2 As shown, the molding unit is equipped with a mold mounting frame, which adopts a modular design and is equipped with 11 zero-point positioning devices (such as...). Figure 4 (As shown) includes 15 positioning Latin and 16 zero-point positioning plate, which facilitates the replacement of molds of different shapes; multiple molds can be installed in the molding unit for simultaneous production; the mold 6 includes 8 upper mold and 9 lower mold, the upper mold is driven by 10 pneumatic drive system including 12 precision pressure regulating valve to adjust the pressure, 13 guide shaft to specify the direction of mold movement and 14 solenoid valve to control the cylinder to lift and lower to achieve up and down movement, and the lower mold is fixed at the bottom of the molding unit.

[0043] Each upper mold is individually controlled; the surface of the lower mold is treated with wear-resistant and corrosion-resistant materials; the main structure of the molding unit is made of high-strength alloy steel.

[0044] The cold air cooling device includes a cold air radiator and a high-speed fan; the cold air radiator is made of aluminum alloy; multiple cold air radiators and high-speed fans are provided, which can quickly and evenly blow cold air onto the core material after molding, so that it can be cooled and shaped in a short time.

[0045] like Figure 3 As shown, the cutting unit is equipped with multiple die-cutting molds 7. The die-cutting molds are installed using a zero-point positioning device 11, which can quickly complete the replacement and adjustment of the die-cutting molds. The cutting unit is also equipped with a high-precision pneumatic drive system 10 to ensure that the cutting tool runs smoothly and is accurately positioned. The cutting tool is made of a special alloy material with high hardness and high wear resistance, and can be replaced according to different cutting shapes and thickness requirements.

[0046] The conveyor belt is made of high-strength, high-temperature resistant rubber or special engineering plastic with a certain degree of flexibility. Its running speed is infinitely adjustable to ensure that the core material is transported smoothly and at a uniform speed to each processing station.

[0047] Example 2

[0048] An integrated air fiber hot pressing and shaping method, using the equipment described in Example 1 above for hot pressing and shaping, includes the following process flow:

[0049] Equipment Debugging and Preparation: Before production, first inspect the main equipment to ensure that all components of the conveyor belt, hot air unit, molding unit, cooling air device, and cutting unit are securely connected, the electrical circuits are normal, and the lubrication system is in good condition. Debug the temperature control system of the hot air unit, the air pressure system of the molding unit, the fan and radiator of the cooling air device, and the guide rails and drive system of the straight blade cutting unit to ensure that the parameters of each piece of equipment meet the set requirements.

[0050] Core material preparation: Cut and lay the air fiber core material according to the product specifications, ensuring that the core material surface is flat and wrinkle-free, place it on the conveyor belt and fix the starting position.

[0051] Start production: Click the start button. The conveyor belt will run at the set speed, transporting the core material to the hot air unit. During the operation of the hot air unit, closely monitor the temperature display and the working status of the heating elements to ensure that the core material is heated at 110℃ for 30 seconds.

[0052] Molding process: After the core material enters the molding unit, the corresponding mold is selected and installed in the molding unit according to the required product shape. After the mold is installed, the installation accuracy and sealing of the mold are checked. The molding program is started, the upper mold is lowered and pressurized to 0.15 MPa, and the pressure is held for 2 minutes. At the same time, the cold air cooling device is started to ensure that the core material cools and solidifies rapidly after molding.

[0053] Cutting process: Install the corresponding die according to the product shape. After the die is installed, perform a trial cut to check the cutting dimensions and quality. Once confirmed to be correct, proceed with the formal cutting of the cooled and shaped core material.

[0054] Finished Product Processing: After cutting, the finished products are conveyed out by a conveyor belt. Operators conduct quality inspections on the finished products, checking whether their shape, size, surface quality, etc., meet the requirements. Qualified products are packaged and stored, while unqualified products are labeled and classified for further processing.

[0055] Equipment maintenance: After production is completed, the equipment is cleaned and maintained, removing debris and dust from the surface and inside of the equipment, and the transmission components and lubrication system are inspected and maintained to prepare for the next production run.

[0056] Example 3

[0057] An integrated air fiber hot pressing and shaping method, using the equipment described in Example 1 above for hot pressing and shaping, includes the following process flow:

[0058] Equipment Debugging and Preparation: Before production, first inspect the main equipment to ensure that all components of the conveyor belt, hot air unit, molding unit, cooling air device, and cutting unit are securely connected, the electrical circuits are normal, and the lubrication system is in good condition. Debug the temperature control system of the hot air unit, the air pressure system of the molding unit, the fan and radiator of the cooling air device, and the guide rails and drive system of the straight blade cutting unit to ensure that the parameters of each piece of equipment meet the set requirements.

[0059] Core material preparation: Cut and lay the air fiber core material according to the product specifications, ensuring that the core material surface is flat and wrinkle-free, place it on the conveyor belt and fix the starting position.

[0060] Start production: Click the start button. The conveyor belt will run at the set speed, transporting the core material to the hot air unit. During the operation of the hot air unit, closely monitor the temperature display and the working status of the heating elements to ensure that the core material is heated at 80℃ for 60 seconds.

[0061] Molding Process: After the core material enters the molding unit, select the corresponding mold (please provide a specific shape) according to the required product shape and install it in the molding unit. After the mold is installed, check the installation accuracy and sealing of the mold. Start the molding program, the upper mold descends and pressurizes to 0.1 MPa, holds the pressure for 3 minutes, and simultaneously activates the cold air cooling device to ensure that the core material cools and solidifies rapidly after molding.

[0062] Cutting process: Install the corresponding die according to the product shape. After the die is installed, perform a trial cut to check the cutting dimensions and quality. Once confirmed to be correct, proceed with the formal cutting of the cooled and shaped core material.

[0063] Finished Product Processing: After cutting, the finished products are conveyed out by a conveyor belt. Operators conduct quality inspections on the finished products, checking whether their shape, size, surface quality, etc., meet the requirements. Qualified products are packaged and stored, while unqualified products are labeled and classified for further processing.

[0064] Equipment maintenance: After production is completed, the equipment is cleaned and maintained, removing debris and dust from the surface and inside of the equipment, and the transmission components and lubrication system are inspected and maintained to prepare for the next production run.

[0065] Example 4

[0066] An integrated air fiber hot pressing and shaping method, using the equipment described in Example 1 above for hot pressing and shaping, includes the following process flow:

[0067] Equipment Debugging and Preparation: Before production, first inspect the main equipment to ensure that all components of the conveyor belt, hot air unit, molding unit, cooling air device, and cutting unit are securely connected, the electrical circuits are normal, and the lubrication system is in good condition. Debug the temperature control system of the hot air unit, the air pressure system of the molding unit, the fan and radiator of the cooling air device, and the guide rails and drive system of the straight blade cutting unit to ensure that the parameters of each piece of equipment meet the set requirements.

[0068] Core material preparation: Cut and lay the air fiber core material according to the product specifications, ensuring that the core material surface is flat and wrinkle-free, place it on the conveyor belt and fix the starting position.

[0069] Start production: Click the start button. The conveyor belt will run at the set speed, transporting the core material to the hot air unit. During the operation of the hot air unit, closely monitor the temperature display and the working status of the heating elements to ensure that the core material is heated at 120℃ for 20 seconds.

[0070] Molding Process: After the core material enters the molding unit, select the corresponding mold (please provide a specific shape) according to the required product shape and install it in the molding unit. After the mold is installed, check the installation accuracy and sealing of the mold. Start the molding program, the upper mold descends and pressurizes to 0.3 MPa, holds the pressure for 1 minute, and simultaneously activates the cold air cooling device to ensure that the core material cools and solidifies rapidly after molding.

[0071] Cutting process: Install the corresponding die according to the product shape. After the die is installed, perform a trial cut to check the cutting dimensions and quality. Once confirmed to be correct, proceed with the formal cutting of the cooled and shaped core material.

[0072] Finished Product Processing: After cutting, the finished products are conveyed out by a conveyor belt. Operators conduct quality inspections on the finished products, checking whether their shape, size, surface quality, etc., meet the requirements. Qualified products are packaged and stored, while unqualified products are labeled and classified for further processing.

[0073] Equipment maintenance: After production is completed, the equipment is cleaned and maintained, removing debris and dust from the surface and inside of the equipment, and the transmission components and lubrication system are inspected and maintained to prepare for the next production run.

[0074] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions claimed by the present invention.

Claims

1. An integrated air fiber hot pressing and shaping device, characterized in that, It includes the following structure: a hot air unit, a molding unit, and a cutting unit, which are connected by a conveyor belt. The molding unit is equipped with a cold air cooling device.

2. The integrated air fiber hot pressing and shaping equipment according to claim 1, characterized in that, The hot air unit generates hot air through electric heating. The hot air unit is also equipped with a circulating fan, which makes the hot air circulate in the hot air box, so as to heat the core material quickly and evenly.

3. The integrated air fiber hot pressing and shaping equipment according to claim 2, characterized in that, The hot air unit is also equipped with a whole-machine protection system, which includes an over-temperature protection device and an alarm device. When the actual temperature exceeds the control temperature, the over-temperature protection device stops the hot air unit from heating, and the alarm device issues an alarm.

4. The integrated air fiber hot pressing and shaping equipment according to claim 1, characterized in that, The molding unit is equipped with a mold mounting frame, which adopts a modular design to facilitate the replacement of molds of different shapes. Multiple molds can be installed in the molding unit for simultaneous production. The mold includes an upper mold and a lower mold. The upper mold moves up and down through a pneumatic drive device, and the lower mold is fixed to the bottom of the molding unit.

5. The integrated air fiber hot pressing and shaping equipment according to claim 4, characterized in that, Each upper mold is individually controlled; the surface of the lower mold is treated with wear-resistant and corrosion-resistant materials; the main structure of the molding unit is made of high-strength alloy steel.

6. The integrated air fiber hot pressing and shaping equipment according to claim 1, characterized in that, The cold air cooling device includes a cold air radiator and a high-speed fan; the cold air radiator is made of aluminum alloy; multiple cold air radiators and high-speed fans are provided, which can quickly and evenly blow cold air onto the core material after molding, so that it can be cooled and shaped in a short time.

7. The integrated air fiber hot pressing and shaping equipment according to claim 1, characterized in that, The cutting unit is equipped with multiple cutting dies, which are installed using a quick-positioning clamping device, enabling rapid replacement and adjustment of the cutting dies. The cutting unit is also equipped with a high-precision linear guide rail and a pneumatic drive system to ensure smooth operation and accurate positioning of the cutting tools. The cutting tools are made of a special alloy material with high hardness and high wear resistance, and can be replaced according to different cutting shapes and thickness requirements.

8. The integrated air fiber hot pressing and shaping equipment according to claim 1, characterized in that, The conveyor belt is made of high-strength, high-temperature resistant rubber or special engineering plastic with a certain degree of flexibility. Its running speed is infinitely adjustable to ensure that the core material is transported smoothly and at a uniform speed to each processing station.

9. An integrated method for hot-pressing and shaping air fibers, characterized in that, Processing using the hot pressing and shaping equipment according to any one of claims 1-8 includes the following process flow: (1) Core material preparation: The air fiber core material is laid flat on the conveyor belt. The operator clicks the start button and the conveyor belt starts to run at the set speed. (2) Heating: The conveyor belt smoothly transports the air fiber core material to the hot air unit. During this period, the heating element and the circulating fan of the hot air unit work together to fully wrap the air fiber core material with hot air and heat it. The air fiber core material stays in the hot air unit for a period of time and gradually softens under the action of hot air, reaching a moldable state. (3) Molding and shaping: The softened air fiber core material is conveyed to the molding unit by the needle plate chain. The operator selects the corresponding mold according to the required product shape and installs it in the molding unit. When the core material reaches the molding position, the upper mold is rapidly lowered and pressurized under the action of the air pressure drive device and the pressure is maintained for a period of time. During the pressurization process, the upper and lower surfaces of the mold are in full contact with the core material, causing the core material to undergo plastic deformation to conform to the shape of the mold under pressure. (4) Cooling and shaping: After the molding is completed, the cold air device is started. The high-speed fan blows the cold air through the air-cooled heat sink to accelerate the cooling and then blows it evenly onto the core material in the molding. The cold air quickly cools the core material, and the upper mold rises rapidly under the action of the air pressure drive device to complete the shaping process. (5) Cutting: After cooling and shaping, the core material enters the cutting process. The operator installs the corresponding die according to the product shape. The air pressure of the straight cutter unit drives the cutting tool to cut the core material according to the preset cutting path. During the cutting process, the linear guide rail ensures the straightness and accuracy of the tool movement and ensures the accuracy of the cutting size. (6) Quality inspection and packaging: After cutting, the finished product is conveyed out by the conveyor belt. The operator conducts quality inspection and packaging of the finished product, and the whole process is completed.

10. The integrated air fiber hot pressing and shaping method according to claim 9, characterized in that, In step 2, the air fiber is heated to 80-120℃ and the air fiber stays in the hot air unit for 20-60 seconds; in step 3, the upper mold is pressurized to 0.1-0.3 MPa and the pressure holding time is 1-3 minutes.

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